Riskex IPS Work Procedure and Permit

Insulated Sandwich Panel (ISP) Procedure
1. PURPOSE
The purpose of the ISP Work Procedures is to ensure that any work carried out on ISP
follows the appropriate Standard Work Procedure.
To ensure that COMPANY assets and property are not put at risk when work is required
on ISP. The work procedures must be followed regardless of the scale of work.
2. SCOPE
Work on ISP shall be understood to mean :
 Install or demolish ISP panel

 Make a penetration through either or both skins of an ISP panel
 Mount equipment or either skin of an ISP panel
 Effect repairs to either skin
The Engineering team has the responsibility of maintaining and developing these ISP
Standard Work Procedures.
NOTE: NO HOT WORK IS PERMITTED ON ISP UNDER ANY CIRCUMSTANCES.
3. ISP STANDARD WORK PROCEDURES
ISP – WP 1 Standard Work Procedure for sealing penetrations through ISP made
for pipes and conduits.
for cable run into cool rooms or freezers.
for single or multiple lagged pipes.
ISP – WP 4 Standard Work Procedure for sealing large penetrations through ISP
made for ductwork.
ISP – WP 5 Standard Work Procedure for sealing large penetrations through ISP
made for groups of pipes and cable ladder.
ISP – WP 6 Standard Work Procedure for mounting equipment on ISP.
ISP – WP 7 Standard wok procedure for repairing ISP
4. REFERENCES
Federal
Occupational Health and Safety (Commonwealth Employment) Act 1991
Applicable to Victoria
Occupational Health and Safety Act 2004
Victorian OH&S Working at Heights Regulations
Applicable to NSW
Occupational Health & Safety Act 2000
Occupational Health & Safety Regulations 2001
Applicable to Queensland
Workplace Health & Safety Act 1995
Workplace Health & Safety Regulations 1997
Applicable to South Australia

Occupational Health, Safety and Welfare Act 1986
Occupational Health, Safety and Welfare Regulations 1995
Applicable to Western Australia
Occupational Safety & Health Act 1984
Applicable to Northern Territory
Work Health Act
Riskex Page 1 of 15 Issued: May 2010

Insulated Sandwich Panel (ISP) PRINTED COPIES ARE UNCONTROLLED Revision: original
Procedure
Work Health (Occupational Health & Safety) Regulations 1992

Applicable to Tasmania
Workplace Health & Safety Act 1995
Workplace Health & Safety Regulations 1998
Applicable to ACT
Occupational Health & Safety Act
5. ROLES & RESPONSIBILITIES
Only qualified maintenance contractors are permitted to carry out any work on ISP and
must have prior approval and sign off on correct procedures by the Property Team, site
manager/ work supervisor.
Where none of the work procedures appear to be appropriate for the job at hand, advice
from the Engineering team must be obtained. The following applies for all work on ISPs:
• The Property Team must have full notice of any work to be completed
• Permits are to be issued for all new works and repairs.
• Permits can only be issued by supervisors or managers with the Property Team’s
approval.
• Permits can be issued to employees and contractors.
• Permit holders must be trained and competent in performing the works covered by
the issued permit.
All COMPANY employees , contractors and visitors are required to comply with these
procedures
All issued and signed off permits are to be held on file for audit and review for
at least twelve months by the manager
NOTE: NO HOT WORK IS PERMITTED ON ISP UNDER ANY CIRCUMSTANCES.

Procedure
6. PROCEDURES
6.1 PROCESS FLOW CHART

Procedure
6.2 PROCEDURES
ISP – WP 1 Standard Word Procedure for sealing penetrations through ISP

made for pipes and conduits.
Objective: To ensure that when a penetration is made through ISP for pipes and
conduits
 That the penetration is made using the hole saw without generating enough heat
to ignite the styrene.
 That the vapour seal is made good.
 That the flashing and sealing is applied to both sides of the ISP and is at least
equal to the skin of the ISP.
 That the flashing and sealing does not harbour dirt or product.
Procedure:
1) Using a hole say, make a hole through the ISP. The diameter of the hole should be
as close to the diameter of the pipe or conduit as possible. Refer to diagram ISP
WP1.
2) Pass the pipe or conduit through a suitably sized expansion flange, through the ISP
and through a second expansion flange.
3) For both expansion flanges,
a) Position the inner flange against the ISP
b) Press the O ring firmly into position against the inner flange
c) Apply silicone sealant between the outer flange and the ISP and screw fix
the outer flange into place.
d) Remove excess silicone sealant.
e) Confirm that the o-ring is compressed between the flange and the pipe or
conduit.
Expansion flanges are not readily available for pipes with a diameter less than 19mm.
For pipes smaller than 19mm,
1) Fabricate flashing rings from colour bond sheeting. Ensure that the pipe fits neatly
through the rings.
2) Apply Silicone sealant between the ring and the ISP and fix the rings in place using
blind rivets. Remove excess sealant.

Procedure
ISP - WP1

Procedure
ISP – WP 2 Standard Work Procedure for sealing penetrations through ISP made for cable
run into cool rooms or freezers.
Objective: To ensure that when a penetration is made through ISP for cable
 That the penetration is made using a hole saw without generating enough heat to ignite the
styrene.
 That the sealing applied to both sides of the ISP is at least equal to the skin of the ISP.
 That the silicone seal does not harbour dirt.
Conduits carrying cable or wiring are not to be run into cool rooms or freezers under any
circumstances.
Procedure:
1) Using the hole saw, make a hole through the ISP. The diameter of the hole should be as close to
the diameter of the conduit as possible. Refer to diagram ISP WP2.
2) Cut a piece of conduit 20mm longer than the thickness of the ISP being penetrated. This will
allow the conduit to extend 10mm past the skin on either side of the ISP.
3) Apply silicone sealant to the outside of the conduit and insert the piece of conduit into the hole
making sure there is a seal between the ISP and the conduit on both sides of the ISP. Pay
particular attention to the seal on the warm side of the ISP.
4) After the silicone sealant has set, pass the cable through the conduit and apply silicone sealant
between the conduit and the cable at both ends of the conduit.
ISP – WP 2

Procedure
SP – WP 3 Standard Work Procedure for sealing penetrations through ISP made for
single or multiple lagged pipes.
Objective: To ensure that when a penetration is made through ISP for lagged pipes
 That the penetration is made using a ‘beater saw’, jigsaw or hole saw without generating
enough heat to ignite the styrene.
 That any void created is filled with closed cell polyurethane expanding foam.
Procedure:
1) Create an opening in the ISP sufficiently large enough to allow the pipe to pass through and to
have it’s lagging applied. Where the penetration through the ISP is too large to be made with a
hole saw a square or rectangular penetration is acceptable. Refer to diagram ISP WP3.
2) Install the pipe and apply the pipe lagging making sure the lagging is continuous through the
penetration in the ISP. All components of the lagging should be applied at this stage, with the
exception of any external metal cladding.
3) For each side of the ISP, fabricate flashing from two pieces of white Colour Bond sheeting
equivalent to the ISP skin. Ensure that the flashing overlaps the penetration by at least 50mm.
Apply silicone sealant between the flashing and ISP and fix in place with blind rivets. Remove
any excess silicone sealant.
4) Make a small hole in the flashing and fill the void with expanding polyurethane foam. Trim away
excess foam and plug the hole.
5) Fit metal cladding to the lagged pipe work if metal cladding has been specified.
SP – WP 3

Procedure
ISP – WP 4 Standard Work Procedure for sealing large penetrations through ISP made for
ductwork.
Objective: To ensure that when a penetration is made through ISP for ductwork:
 That the penetration is made using a ‘beater saw’ or jigsaw without generating enough heat to
ignite the styrene.
Procedure:
1) Create an opening in the ISP 20mm wider and 20mm deeper than the duct that will pass through
it using a beater saw or jig saw.
2) For a duct passing through ISP other than into a refrigerated space: See diagram ISP WP4.
(a.) Fabricate aluminium channel flashing to cover the exposed ISP core. Apply silicone sealant
between the flashing and ISP and fix in place with blind rivets.
(b.) Fabricate aluminium or fibreglass angle flashing to cover the gap between the channel and
the duct on both sides of the ISP. Apply a continuous bead of silicone sealant between all
mating surfaces and fix in place with blind rivets.
3) For a duct passing into a refrigerated space see diagram ISP WP4.
(a.) Fabricate aluminium or fibreglass angle flashing that when installed will almost cover the
ISP core. Ensure that the inside and outside flashing can’t come into contact.
(b.) Apply silicone sealant between the flashing and the ISP and fix in place with blind rivets.
(c.) Apply a bead of silicone sealant between the inside and outside flashing to seal the exposed
ISP core.
(d.) Fabricate aluminium or fibreglass angle flashing to cover the gap between the first flashing
and the duct on both sides of the ISP. Apply a continuous bead of silicone sealant between
all mating surfaces and fix in place with blind rivets. XYZ Pty Ltd ISP Procedures - ISP WP4
ISP – WP 4

Procedure
ISP – WP 5 Standard Work Procedure for sealing large penetrations through ISP made for
groups of pipes and cable ladder.
Objective: To ensure that when a penetration is made through ISP for large groups of pipes:
 That the penetration is made using a ‘beater saw’ or jigsaw without generating enough heat to
ignite the styrene.
Note: This procedure can not be used for pipe penetrations into cool rooms
Work procedure ISP WP1 or ISP WP 3 must be used.
Procedure:
1) Create the required opening in the ISP. See diagram ISP WP5.
2) Fabricate aluminium channel flashing to cover the exposed ISP core. Apply silicone sealant
between the flashing and ISP and fix in place with blind rivets.
3) Remove excess sealant.
ISP – WP 5

Procedure
ISP – WP 6 Standard Work Procedure for mounting equipment on ISP.
Objective: To ensure that when equipment is mounted in an ISP wall or ceiling:

 That the equipment can not transfer enough heat to the ISP to ignite the core.
 That the skin of the ISP does not delaminate from the core.
 That dirt or product will not be trapped between the equipment and the wall or
ceiling.
 That an electrical hazard is not created.
Generally, ISP walls should be left as clear of equipment as possible.

Alternative mounting procedures should be identified for equipment weighing more than
10kg. Alternatives that should be considered include floor mounting equipment and
suspending or supporting the equipment from structural building elements.
Procedure:
1) For flush mounted equipment e.g. Light switches, power outlets, emergency stop
buttons, containers for hairnets and earplugs etc.:
(a.) Mark and drill pilot holes. For electrical equipment make sure that the position
of the mounting holes maintains double insulation between live parts and the
fixing screw. Otherwise earth the mounting screw.
(b.) Apply silicone sealant between the mating surfaces of the equipment and the
ISP.
(c.) Fix the equipment in place with self tapping screws or blind rivets.
(d.) Remove excess sealant.
Note: All conduits installed in processing and cool room areas must be spaced from the
wall. The objective is to ensure that the instillation can be effectively cleaned.
2) For equipment that exceeds 10 kg or that could be subjected to significant forces,
for example, a fire hose reel:
(a.) Mark and drill clearance holes through the ISP at the mounting points.
(b.) Make allowances to spread the load on both sides of the ISP by using large (at
least 100 cm²) stainless steel plates or hot dipped galvanised Unistrut.
(c.) Apply silicone sealant between the ISP and any faces of the plates or of the
structure that make more than point contact with it.
(d.) Use stainless steel nuts and bolts or stainless steel threaded rod and nuts to
bolt through the assembly.
(e.) Do not over tighten the assembly because this may damage the ISP.
(f.) Remove excess sealant.

Procedure
3) For surface mounted light fittings ensure that the fitting is mounted flush to the
ceiling and that no voids exist between the light fitting and the ceiling panel. In
hygiene areas the fitting must be rated IP 67 and the diffuser must be smooth on
the outside.
4) For recessed light fittings: refer to diagram ISP WP6
(a.) The light fitting to be recessed must have a metal casing designed to be recess
mounted. Size the opening in the ISP to be as close to the external dimensions
of the light fitting as possible.
(b.) Make the opening in the ISP using a beater saw or jig saw.
(c.) Run a continuous bead of silicone sealant between mating surfaces of the light
fitting and the ISP on the “cold” side of the panel and install the light fitting.
Fix it in place with blind rivets.
(d.) Fabricate flashing to re-form the vapour seal on the “warm” side of the ISP.
Apply a continuous bead of silicone sealant between mating surfaces and fix
the flashing to the ISP with blind rivets. Avoid fixing the flashing to the light
fitting.
(e.) If the ceiling space in the area of the light fitting is trafficable, fabricate and
install an expanded metal top hat over the fitting that will prevent a person
stepping on the fitting.
ISP – WP 6

Procedure
ISP – WP 7 Standard wok procedure for repairing ISP
Most damage to ISP results in one skin of a panel being dented or torn. This work procedure
addresses the repair of this type of damage. Panel damaged to such an extent that both skins
are creased should be replaced.
Objective: When repairing damaged ISP it is necessary to make sure:
 That when the damaged material is cut away without generating enough heat to ignite
the styrene.
Procedure: - to be used when the core is gouged
1) Mark a square or rectangular area on the damaged skin that completely contains the
damaged area of ISP.
2) Using a jig saw cut through the ISP skin and remove the marked area of skin.
3) Use a sharp knife to cut in line with the edge of the opening, through the styrene to the
other skin of the ISP.
4) Remove the styrene.
5) Cut a piece of ISP the same thickness as the panel under repair. The piece should overlap
the opening by 40 – 50 mm on each side.
6) Remove one skin from the piece of panel and trim the styrene to be a neat, tight fit in the
opening.
7) Apply silicone sealant between the mating surfaces and fix the plug in place with blind
rivets.
Alternative procedure - to be used when the core is not damaged

9) Mark a square or rectangular area on the damaged skin that completely contains the
damaged area of ISP.
10) Using a jig saw or beater saw cut through the ISP skin and remove the marked area of
skin.
11) Fabricate a piece of colour bond sheeting, sized to overlap the area of exposed styrene
core by 40 – 50 mm on all sides.
12) Apply silicone sealant between mating surfaces and fix the patch in place with blind rivets.

Procedure
7. RECORDS/ DOCUMENTATION
Minimum Time Minimum Time
Record Custodian Location
Filed Archived
Insulated Maintenance Maintenance Office 2 years or until Nil
Sandwich Panel Manager replaced
(ISP) Work Permit
Working at Height Maintenance Maintenance Office 2 years or until Nil

Permits Manager replaced
Hot Work Permits Maintenance Maintenance Office 2 years or until Nil
Manager replaced
8. REFERENCES
SWS No. 3.3 Contractor & Visitor Management
SWS 3.6 Electrical Safety
SWS 3.8 Hazardous Materials
SWS 3.13 Permit to Work

Procedure
APPENDIX – A – INSULATED SANDWICH PANEL (ISP) WORK PERMIT

Procedure
INSULATED SANDWICH PANEL (ISP) WORK PERMIT

It is important when making any penetrations though ISP to make sure the polystyrene foam is not left
exposed. If exposed, it provides any easy way for the core of the ISP to catch on fire. This procedure is
designed to address this issue by ensuring we install and manage ISP in a consistent procedure.
HOT WORK IS NOT TO BE CARRIED OUT ON INSULATED SANDWICH PANEL.
ISP WORK PERMIT

LOCATION:
DEPARTMENT: DATE:
Commencement Time: Expected Duration:
EQUIPMENT:
WORK TO BE PERFORMED: ________________________________________________________
________________________________________________________
WORK TO BE PERFORMED
BY:
STANDARD PRECAUTIONS:  No hot cutting, oxy welding or grinding of panels.
 Operating equipment shut down and isolated where appropriate.
 The work areas clean and free from debris and flammable
materials.
 Confined spaces are to be checked for poisonous and flammable
M gases and dust and oxygen levels.
A  Notify department manager / supervisor of the intent to work.
I  All equipment checked for good repair.
N  Sharp tools only are to be used
T  Use slow speed cutters and tin snips
E  Non-spark producing tools, drill, cutters, etc to be used
N  Exposed foam core resealed with non-combustible face at
A completion of work (i.e. no exposed foam core).
N SPECIAL PRECAUTIONS
C (As Specified by ISP Standard
E Work Procedures)
WORK AUTHORISED BY: Signed:
Print Name:
Position:
WORK ACCEPTANCE: I have been fully briefed and understand the work to be performed. I
am fully aware of the standard and special safety precautions as
outlined above and agree to abide by these precautions.
Signed: Print Name:

EQUIPMENT ISOLATION: Actual equipment isolated:
(If Applicable) Equipment isolated electrically and removed from service by:
Signed: Print Name:

FINAL POST WORK CHECK: I have checked the area at the completion of the work. All penetrations
were found to be sealed and no exposed foam core or other hazardous
panel conditions were noted.
Signed: Print Name:
THIS PERMIT MUST BE USED BY ALL PERSONNEL & CONTRACTORS WHEN WORKING ON ISP.

Procedure

Riskex IPS Work Procedure and Permit

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Insulated Sandwich Panel (ISP) Procedure

 Install or demolish ISP panel

3. ISP STANDARD WORK PROCEDURES

Applicable to South Australia

Riskex Page 1 of 15 Issued: May 2010

Work Health (Occupational Health & Safety) Regulations 1992

5. ROLES & RESPONSIBILITIES

• Permits can be issued to employees and contractors.

NOTE: NO HOT WORK IS PERMITTED ON ISP UNDER ANY CIRCUMSTANCES.

Riskex Page 2 of 15 Issued: May 2010

Riskex Page 3 of 15 Issued: May 2010

ISP – WP 1 Standard Word Procedure for sealing penetrations through ISP

Riskex Page 4 of 15 Issued: May 2010

Riskex Page 5 of 15 Issued: May 2010

 That the vapour seal is made good.

 That the silicone seal does not harbour dirt.

Riskex Page 6 of 15 Issued: May 2010

Riskex Page 7 of 15 Issued: May 2010

Riskex Page 8 of 15 Issued: May 2010

 That the vapour seal is made good.

Riskex Page 9 of 15 Issued: May 2010

ISP – WP 6 Standard Work Procedure for mounting equipment on ISP.

Objective: To ensure that when equipment is mounted in an ISP wall or ceiling:

 That the vapour seal is made good.

 That an electrical hazard is not created.

Generally, ISP walls should be left as clear of equipment as possible.

(d.) Remove excess sealant.

(f.) Remove excess sealant.

Riskex Page 10 of 15 Issued: May 2010

4) For recessed light fittings: refer to diagram ISP WP6

Riskex Page 11 of 15 Issued: May 2010

ISP – WP 7 Standard wok procedure for repairing ISP

Objective: When repairing damaged ISP it is necessary to make sure:

Procedure: - to be used when the core is gouged

4) Remove the styrene.

8) Remove excess sealant.

Alternative procedure - to be used when the core is not damaged

13) Remove excess sealant.

Riskex Page 12 of 15 Issued: May 2010

Working at Height Maintenance Maintenance Office 2 years or until Nil

SWS No. 3.3 Contractor & Visitor Management

SWS 3.6 Electrical Safety

SWS 3.8 Hazardous Materials

SWS 3.13 Permit to Work

Riskex Page 13 of 15 Issued: May 2010

APPENDIX – A – INSULATED SANDWICH PANEL (ISP) WORK PERMIT

Riskex Page 14 of 15 Issued: May 2010

INSULATED SANDWICH PANEL (ISP) WORK PERMIT

HOT WORK IS NOT TO BE CARRIED OUT ON INSULATED SANDWICH PANEL.

ISP WORK PERMIT

Signed: Print Name:

Signed: Print Name:

Signed: Print Name:

Riskex Page 15 of 15 Issued: May 2010

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